GKN Aerospace develops the future of aviation technology

GKN Aerospace Kongsberg has been involved in the development of a shaft that makes future aviation technology greener and more sustainable.

GKN is constantly working towards environmentally friendly aviation.

It is no secret that aviation is a source of pollution. Increasingly, countries and international organizations are raising awareness and promoting policy measures to limit climate change and the environmental impact of aviation.

– That is why it is so important that GKN works every day to develop new technology and products that make aviation more environmentally friendly. Europe needs competitive and sustainable air transport. We can offer that by being a part of the Clean Sky 2 project, says Eivind Bakke, Team Leader for System Support at GKN Aerospace Engine Systems Norway.

What is a shaft?

The shaft, or axle, is a rotating component subjected to very strong forces. It connects the turbine to the compressor and covers most of the length of the engine.

There can be up to three concentric shafts rotating at independent speeds, with an equal number of sets of turbines and compressors. Cooling air for the turbines can flow through the shaft from the compressor.

The material of the shaft is typically resistant steel alloys.

Key objectives of the project are:

To increase aircraft fuel efficiency, thereby reducing CO2 emissions by 20-30% compared to state-of-the-art aircraft.
To reduce aircraft NOx and noise emissions by 20-30% compared to state-of-the-art aircraft.

What is a shaft?

The shaft, or axle, is a rotating component subjected to very strong forces. It connects the turbine to the compressor and covers most of the length of the engine.

The material of the shaft is typically resistant steel alloys.

Key objectives of the project are:

To increase aircraft fuel efficiency, thereby reducing CO2 emissions by 20-30% compared to state-of-the-art aircraft.
To reduce aircraft NOx and noise emissions by 20-30% compared to state-of-the-art aircraft.

Increased efficiency, lower CO2 emissions, and reduced noise

The Clean Sky 2 research program is an initiative for greener aviation. The project started in 2008 with the goal of developing aircraft engines with increased efficiency, lower CO2 emissions, and reduced noise.

The program is a collaboration between the European Commission and several European companies in the aviation industry, including GKN Aerospace.

Clean Sky 2 is a demonstration project, meaning that all components and new technologies are developed and tested at full scale. It is the largest European research and innovation project in aeronautics to date.

The most effective means of reducing CO2 emissions

As part of the Clean Sky 2 program, GKN Aerospace contributes its expertise and innovative technology to develop more sustainable and efficient aircraft. At the Kongsberg facility, they have produced a shaft for a test rig on an aircraft engine demonstrator to test the new technology.

– The shaft for the test rig was ordered by the German aircraft engine manufacturer MTU Aero Engines through GKN Sweden, and the project leaders at GKN Sweden saw the opportunity to utilize the shaft expertise at GKN in Kongsberg, explains Eivind Bakke enthusiastically.

In the Strategic Research and Innovation Agenda (SRIA) of the Advisory Council for Aviation Research and Innovation in Europe (ACARE), Clean Sky is identified as probably the most effective means of reducing CO2 emissions.

A comprehensive project

The project has gone through many different phases since its inception in 2008. In 2021, the project reached the testing stage. In 2022, the production of the individual part began. In 2023, the subproject is in the assembly phase, with the next phase being the testing phase.

– The entire Clean Sky project is extensive and includes many subprojects in engines, aerodynamics, and other configurations, Bakke explains.

An exciting and educational project

The project participants at GKN Aerospace Norway provided input for the shaft’s design and production process.

– Many people in operations, technical, and method ownership at GKN have been involved in the production of the shaft, which was completed and sent just before Easter 2023. It will now proceed to the assembly test at GKN in Trollhättan and then to the assembly at MTU in Munich, says Bakke.

He doesn’t hide the fact that it has occasionally been a challenging project.

– There were some bumps and delays along the way, but the communication and collaboration with both GAS (GKN Aerospace Sweden) and MTU were good. The project was highly educational and gained a lot of experience.

Strengthened collaboration

GKN would like to thank everyone who has contributed to the project.

– Clean Sky 2 has contributed to strengthening GKN’s relationship with MTU, which can lead to new opportunities or contracts in the future, for example, through upcoming phases in Clean Sky. Moreover, the project has contributed to the development of a greener aviation industry of the future, in line with GKN Aerospace’s visions.

Sustainability heroes

At GKN, we are constantly working to optimize and improve sustainability solutions. Therefore, we have assembled a dedicated sustainability team consisting of Urszula Jaciszyn, Roger Moe, and Eilev Aakre. We call them the sustainability heroes.

– Being sustainable is crucial for GKN Aerospace Norway. By focusing on sustainable solutions, we enhance our ability to recruit, experience increased revenue, and gain greater competitiveness. Choosing sustainable solutions does not come at the expense of anything else, explains Eilev Aakre.

Another important aspect for improved sustainability is GKN’s utilization of solar energy. Among other things, we use the sun and solar energy as a power source, as an environmentally friendly alternative to electricity.

– We are working towards replacing all electricity with solar energy. Additive Manufacturing, also known as 3D printing, is another exciting field we are working on. Just imagine – in the future, aircraft parts could be produced in a printer!